SCHUNK FDB 1040 Page 3 Assembly And Operating Manual Download

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Table of contents

02.01|FDB 150, 300, 340, 660, 900, 1040 |en

Table of contents

Glossary ................................................................................................................... 5

1 General .................................................................................................................... 6

1.1 About this manual .................................................................................................... 6

1.1.1 Presentation of Warning Labels .................................................................... 6

1.1.2 Applicable documents ................................................................................... 7

1.1.3 Sizes ............................................................................................................... 7

1.2 Warranty ................................................................................................................... 7

2 Safety ....................................................................................................................... 8

2.1 Intended use ............................................................................................................. 8

2.2 General Safety Guidelines ........................................................................................ 8

2.3 Safety Precautions .................................................................................................... 9

3 Product Overview .................................................................................................... 11

3.1 Tool Collet Systems ................................................................................................ 12

4 Technical Data ......................................................................................................... 13

5 Installation .............................................................................................................. 18

5.1 Inspection of Condition When Delivered ............................................................... 18

5.2 Unpacking and Handling ......................................................................................... 18

5.3 Mounting ................................................................................................................ 18

5.3.1 Axial Mounting Installation ......................................................................... 19

5.4 Pneumatics ............................................................................................................. 20

5.5 Transportation and Protection during Transportation .......................................... 23

5.6 Storage and Preventive Maintenance during Storage ........................................... 23

6 Operation ................................................................................................................ 24

6.1 General Precautions ............................................................................................... 24

6.2 Working Environment ............................................................................................ 25

6.3 Operational Considerations ................................................................................... 25

6.4 Tool Center Point (TCP) Position and Programming .............................................. 26

6.5 Cutter Operation and Burr Selection ..................................................................... 28

6.5.1 Burr Selection Table .................................................................................... 29

7 Troubleshooting ...................................................................................................... 33

8 Maintenance ........................................................................................................... 35

8.1 Recommended Spare Parts .................................................................................... 35

8.2 Preventive Maintenance ........................................................................................ 36

8.2.1 Inspect Pneumatics Lines and Filter Regulator ........................................... 36

8.2.2 Lubrication .................................................................................................. 37

Summary of Contents for FDB 1040

Page 1: ...original manual Deburring spindle FDB 150 300 340 660 900 1040 Assembly and operating manual Superior Clamping and Gripping...

Page 2: ...ion 02 01 30 05 2017 en SCHUNK GmbH Co KG All rights reserved Dear customer congratulations on choosing a SCHUNK product By choosing SCHUNK you have opted for the highest precision top quality and bes...

Page 3: ...vered 18 5 2 Unpacking and Handling 18 5 3 Mounting 18 5 3 1 Axial Mounting Installation 19 5 4 Pneumatics 20 5 5 Transportation and Protection during Transportation 23 5 6 Storage and Preventive Main...

Page 4: ...7 8 2 4 Burr Inspection 37 8 3 Service Procedures 38 8 3 1 Burr Replacement 38 8 3 2 Air Motor Replacement 39 8 3 3 Pivot Bearing Replacement 51 8 3 4 Ring Cylinder Assembly Replacement 59 8 3 5 Spind...

Page 5: ...rkpiece Alterna tively referred to as a rotary file cutter or bit Coalescing Filter Device designed to remove liquid aero sols from the supply air lines Collet Gripping device used to hold cutting too...

Page 6: ...l Illustrations in this manual are provided for basic understanding and may differ from the actual product design In addition to these instructions the documents listed under 1 1 2 Page 7 are applicab...

Page 7: ...ting manual applies to the following sizes FDB 150 FDB 300 FDB 340 FDB 660 FDB 990 FDB 1040 Warranty The warranty of the Deburring spindle is valid for 24 months This does not apply to the air motor T...

Page 8: ...t are not designed to be used with the unit the product is operated without protective equipment in ac cordance to the EC Machinery Directive the statutory safety and accident prevention regulations a...

Page 9: ...eye protection while working in the neighborhood of the deburring tool Never operate the FDB product without wearing eye protec tion CAUTION Using burrs rated for less than the speed of the FDB being...

Page 10: ...glas windows Provide a barrier to prohibit people from approaching the de burring tool while in operation must secure the installation WARNING Injury or equipment damage can occur with tool not docked...

Page 11: ...uality in any orientation The tool also requires no oil allowing clean exhaust air to be vented di rectly into the work environment Compliance is supported by air pressure applied to the shaft of the...

Page 12: ...ted to retain numerous cutter shank diameters The collet retaining nut is loosened to open the collet allowing cutting tools to be re moved and inserted Once the tool is set to the desired depth spann...

Page 13: ...d by means of the bench adapter the robot is carrying the workpiece Temperature range 5 C 35 C Storage Temperature range 5 C 35 C Conditions The tool should be stored in its crate and in a dry place W...

Page 14: ...rface Speed Dependent on cutter geometry and motor speed Spindle Air Pressure 6 2 bar maximum 6 2 6 5 bar 6 9 bar max 6 2 6 5 bar 6 9 bar max Air Consumption Idle 1 42 l s 3 CFM 2 8 l s 6 CFM 2 8 l s...

Page 15: ...max 6 2 6 5 bar 6 9 bar max Air Consumption Idle 5 4 l s 11 5 CFM 8 5 l s 18 CFM 19 l s 18 CFM Air Consumption Stall 17 9 l s 38 CFM 40 CFM 40 CFM Sound Pressure Level Less than 70 dB A without cutter...

Page 16: ...ring tool receives a thorough test procedure be fore it is shipped The following chart shows measured forces relative to applied compliance centering air pressure Measurements may vary from one produc...

Page 17: ...to installation due to mounting orientation and condition of the unit The air turbine will attempt to maintain its full rated speed even under loaded conditions However when extremely heavy cuts are...

Page 18: ...companying box crate during transportation storing and han dling Pneumatic lines and electrical cables are attached bundled and must be strain relieved in a manner that allows for freedom of movement...

Page 19: ...dry non lubricated air filtered five micron or better The use of a coalescing filter is recommended Water and oil damage of the air motor or damage associated with the debris in the air lines is not...

Page 20: ...Installation 20 02 01 FDB 150 300 340 660 900 1040 en Pneumatics Pneumatic Connections FDB 150 and FDB 300 340 Pneumatic Connections FBD 660 FDB 990 FDB 1040 5 4...

Page 21: ...3 Poor performance will result if the correct components are not used Conventional customer supplied pneumatic components are used to control the air supply to the deburring tool SCHUNK recommends tha...

Page 22: ...Applicable It is recommended that flexible plastic tubing be used for the mo tor air supply and the compliance force air supply The installed fit tings can be removed to expose tapped supply ports thu...

Page 23: ...ansporting the deburring tool in order to minimize the risk of damage Storage and Preventive Maintenance during Storage The FDB should be stored in its crate when it is not in use The FDB should also...

Page 24: ...ersinking and other axial metal forming processes should not be performed by the FDB It may be dangerous to operate the FDB debur ring tool for these purposes If a failure occurs due to forces caused...

Page 25: ...t in the cell when the FDB is running Be aware of rotating parts Use eye protection while working around the FDB Be aware of high sound levels While the FDB air motor is not loud the cutting action as...

Page 26: ...lied above a minimum of 1 4 bar FDB 150 or 0 35 bar FDB 300 340 660 990 1040 Two programming methods are suggested but others are possible In the first method a dowel pin of suitable diameter is inser...

Page 27: ...utter from simultaneously contacting two perpendic ular surfaces A tapered cutter may reach further into such an in side corner if the tool is presented in an inclined orientation and closer to the ti...

Page 28: ...ill generally be reduced When conventional milling ex tra care must be taken around corners This poses a potential haz ard where the cutting force can deflect the burr causing the burr to break as the...

Page 29: ...ads and vibrations on the motor bearings resulting in reduced motor life Bearing failure caused by the use of extend ed shank burrs is not covered under warranty CAUTION Long shank tools can lead to p...

Page 30: ...nd tough materials super alloys and stainless steel al loyed cast steel and fiber reinforced plastics Edge and surface working Higher cutting capacity than standard cuts Smoother finish for surface tr...

Page 31: ...and welds For beveling For chamfering For deburring Without chip breaker for scratch free surfaces Diamond Cut 3 8 Burr Diameter 3 4 Burr Length 1 4 Shank For hardened and tough materials super alloys...

Page 32: ...g sticky metals Smooth operation due to the peeling effect of the teeth Cut FVK 1 4 Burr Diameter 5 8 Burr Length 1 4 Shank For trimming and contour milling of all glass and carbon fiber reinforced pl...

Page 33: ...st Reduce feed rate Burr is worn Inspect burr if worn replace 8 3 Page 38 Motor bearings are worn Inspect spindle shaft if shaft feels loose or has play replace 8 3 2 Page 39 Burr Chattering during cu...

Page 34: ...ive air Check drive air regulator for 6 2 Bar and for leaks Burr is not secure in collet Properly tighten burr in collet Too much side load Decrease width of cut make multiple passes Air motor needs r...

Page 35: ...ring maintenance operations refer to 8 3 Page 38 Procedures for maintenance instructions Service and repair parts are identified in Serviceable Parts Recommended Spare Parts For repair and spare parts...

Page 36: ...parts requiring regular maintenance The preventive maintenance of the debur ring tool consists of cleaning the unit and regular inspection for wear or damage of the pneumatic lines filter element spi...

Page 37: ...FDB Pneumatics The air tubing lines to the FDB should routinely be checked for their general condition and replaced as required The air to the FDB must be filtered dry and non lubricated The air filt...

Page 38: ...not be required when the burr is replaced but may be required when a different sized tool is required Collet replacement is included in the following chapters 1 Remove and or lock out the spindle mot...

Page 39: ...arranty The motor may also require re placement after an extended operating life There are no user serviceable parts in the air motor FDB units with defective motors should be returned to SCHUNK durin...

Page 40: ...upply ring around the back of the motor 16 Pull the air supply ring to the rear off the motor 17 Remove the two pieces of tubing from the gimbal ring 18 Locate the two small set screws in the gimbal r...

Page 41: ...surface 27 Press the pivot pin through the housing and into the gimbal ring bearing with the extended inner race Note The under cut band on the pin must be oriented to the outside refer to the figure...

Page 42: ...ew from the center of the deburring unit s rear plate 6 Remove the spindle air supply fitting from the side of the housing by rotating it counter clockwise 7 Ease the garter spring off the front spind...

Page 43: ...pindle air supply fitting from the side of the front housing assembly by rotating the fitting counter clockwise 7 Using a small screw driver remove the internal retaining ring and rubber boot SCHUNK r...

Page 44: ...e rear housing to the front housing using the alignment pin for proper orientation 17 Apply Loctite 222 to the 6 M4 socket head cap screws and se cure the rear housing to the front housing Tighten to...

Page 45: ...ousing assembly 23 Slide the boot onto the air motor and align the edge of the boot to the edge of the contact sleeve 24 Stretch the garter spring over the boot it will seat in the groove on the conta...

Page 46: ...ounter clockwise 6 Using a small screw driver remove the internal retaining ring and rubber boot SCHUNK recommends replacing the internal retaining ring and rubber disk at the spindle supply fitting w...

Page 47: ...rn the bushing in toward the gimbal ring 15 Thread M3 fasteners into the pivot pins 16 At the front of the front housing assembly loosen the 2 M5 set screws securing the motor pivot pins until they ex...

Page 48: ...M5 set screws securing the motor piv ot pins until they extend out of the front housing about 3 mm 21 Using a 2 mm Allen wrench loosen the M4 set screws at the bottom of the motor ring 22 Using a 1 3...

Page 49: ...nto the gimbal ring to secure the pivot pins Tighten to 2 82 Nm 28 Using a 1 3 mm Allen wrench inserted into the side hole of the threaded bushing turn the bushing in toward the gimbal ring until cont...

Page 50: ...s at the bottom of the gimbal ring to 2 82 Nm 35 Apply a coating of Magnalube on the rear post of the air mo tor assembly 36 Apply Loctite 222 to the 6 M4 socket head cap screws 37 Align the rear hous...

Page 51: ...button head socket cap screws Tighten to 2 82 Nm 48 Install the deburring tool to the robot or work location 49 Connect the air hose to the spindle supply fitting and the compliance air fitting 50 App...

Page 52: ...n Air Motor Replacement 8 3 2 1 Page 39 3 The bearings of each ring are now accessible To remove the bearings use a suitable pair of pliers to grab the outer race and pull the bearing out of the ring...

Page 53: ...sing to the deburring tool s front housing 3 Remove the rear cover complete with the pivot bearing Re tain the small o ring and dowel pin between the cover and housing for reuse if desired 4 The new r...

Page 54: ...e reversal of the previous steps with the fol lowing points Insure that the hole in the outer race of the new pivot bear ing lines up with the radial dowel pin hole in the rear hous ing and insert the...

Page 55: ...air supply for safety 2 Disconnect the air hose from the spindle supply fitting and the compliance air fitting 3 Remove the deburring tool from the robot or work location 4 Clean the debris from the d...

Page 56: ...g washer which rests on top of the pivot bearing 12 Loosen the bearing preload set screw in the rear housing 13 Remove the M5 set screws 2x securing the pivot bearing key ing dowel in the rear housing...

Page 57: ...e bottom surface of the keyway is flush with the edge of the outer race 20 Apply Loctite 222 to the M5 set screws 2x used to retain the keying dowel pin While holding the pivot ball in the rotated pos...

Page 58: ...1 35 Nm 28 Apply Loctite 242 to the thread of the socket button head cap screw Insert the washer and tread the socket button head screw into the rear of the air motor While holding the air mo tor to...

Page 59: ...ir motor as described in steps 1 through 14 in 8 3 2 1 Page 39 2 Remove the six socket head cap securing the rear housing to the front housing assembly 3 Remove the rear housing 4 Invert the unit and...

Page 60: ...ay make removal of the compliance unit difficult If this occurs support the front of the housing on a suitable plate with a clearance hole for the ring cylinder and use an arbor press for extraction R...

Page 61: ...Using a small flat head screw driver pry the retaining ring out of the groove in the front housing assembly and remove the retaining ring 5 Press the ring cylinder out of the front housing using a no...

Page 62: ...t dowel pin and insert into the front housing 9 Apply a thin film of Magnalube to the front housing bore where the ring cylinder seats 10 Insert the new ring cylinder into the front housing assembly u...

Page 63: ...ing 3 Remove the deburring tool from the robot or work location 4 Clean the debris from the deburring tool using compressed air and a clean rag to wipe any grease from the outer surfaces 5 Using a 2 m...

Page 64: ...the rear housing NOTICE Be sure O ring stay properly seated into grooves Tighten to 2 82 Nm 13 Assemble the rear housing to the front housing 14 Apply Loctite 222 to the M4 socket head cap screws 6x...

Page 65: ...g the boot ring to the front housing assembly 7 Remove the boot ring and spindle boot 8 Align the spindle boot and the boot ring with the holes in the ring cylinder and slide the boot onto the air mot...

Page 66: ...ing assembly 7 Remove the retaining ring and spindle boot 8 Align the spindle boot and the retaining ring with the holes in the ring cylinder and slide the boot onto the air motor and align the edge o...

Page 67: ...to the product Product designation Deburring spindle FDB 150 300 340 660 900 1040 ID number 0322200 0322201 0322202 0322203 0322205 0322208 0322240 0322245 The incomplete machine may not be put into...

Page 68: ...Translation of original declaration of incorporation 68 02 01 FDB 150 300 340 660 900 1040 en...

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